Method for making specialty tools

ABSTRACT

A METHOD FOR MAKING SPECIALTY TOOLS, a metal forming process for impregnating complex patterns in various tool designs is disclosed herein. According to the process, a blank tool is placed into the first stage  1  of three stages in this automatic rotating/indexing table  10.  A blank tool example being a socket or a wrench. Sensors and a PLC control the automation of the entire process. The holder carries the blank tool to stage two  2  where a free floating punch  48  is driven into the blank tool. After the punch has pulled out of the tool the newly impregnated tool is moved to stage three  3.  In stage three the newly impregnated tool is driven out of the holder by a stationary punch and at the same time a new blank tool is being located into the holder in stage one and a new part is being impregnated in stage two.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The presently invention relates to the process for implementation of complex patterns into a tools interior walls.

2. Description of the Prior Art

The techniques for manufacturing specialty tools and more specifically, sockets are known to consist of the familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.

U.S. Pat. No. 6,339,976 B1 to Jordon discloses a apparatus for cold heading a socket with V-shaped teeth and distorted V-shaped teeth spiraled in a tapered cylinder. In this process the outside body is crushed with a hex pattern which cannot prevent distortion to the interior pattern. Then the tool goes through a secondary cleanup machining process. Adding much time and cost to the tool.

One problem with manufacturing tools for damaged fastener removal is the distortion in the tooth pattern caused by cold heading the tool as noted in the prior art such as described in U.S. Pat. No. 6,339,976 B1. And the complexity of design is not possible.

In this respect, the manufacturing of various complex patterns in specialty tools substantially departs from the conventional concepts, designs and methods of the prior art, and in so doing provides an apparatus primarily developed for the purpose of commercial manufacturing.

Therefore, it can be appreciated that there exists a continuing need for new and improved method for commercial manufacturing of specialty tools. In this regard, the present invention substantially fulfills this need.

SUMMARY OF THE INVENTION

In accordance with the invention, a METHOD FOR MAKING SPECIALTY TOOLS, a metal forming process for impregnating complex patterns in various tool designs is disclosed herein. According to the process, the tool is formed from a blank tool. A blank tool is a tool from a screw machine or cold heading process in which all the exterior machining work has been completed prior to impregnating the desired complex internal pattern. The blank tool has an opening in the interior surface and the outside surface will vary depending on the type of tool and example being a socket or a wrench. The blank tool is placed into a slide and the slide moves the blank tool to the first stage of three stages in this automatic rotating/indexing table. Sensors and a PLC control the automation of the process. A solenoid cylinder lifts the blank tool into a holder. The holder's interior design will match the top and sides of the exterior of the blank tool so the blank tool can be inserted into the holder.

After the blank is located in the holder, the table is rotated, incasing the blank tool on all sides except for the hole where the complex pattern will be impregnated. The holder carries the blank tool to stage two where a floating punch is driven into the blank tool. Floating meaning the punch and holder as a unit can rotate freely in any lateral direction. The pattern design of the punch will depend on the complex pattern desired. The backup plate located under the rotating plate which contains the holders is fixed and has as pocket to hold stamps that can be interchanged which mark the Blank tool as it's interior is being impregnated.

As a blank tool is impregnated a new blank tool is going through the above process of being located in the holder. After the punch has pulled out of the tool the newly impregnated tool, the tool is moved to stage three by the rotation of the table containing the holders. And a new blank part is moved to stage two.

In stage three the newly impregnated tool is driven out of the holder by a stationary punch and at the same time a new blank tool is being located into the holder in stage one and a new part is being impregnated in stage two.

It is therefore an object of the present invention to provide a new and improved method for a metal forming process for impregnating complex patterns in various types of openings. The complex patterns being formed can be straight, tapered, helix and combinations there of, in the internal side walls of various tool designs, such as sockets, wrenches and extractors. This new improved method has all the advantages of the prior and none of the disadvantages.

It is another object of the present invention to provide a new and improved method for a metal forming process for impregnating complex patterns in various tool designs, such as sockets, wrenches and extractors without distorting or damaging the interior or exterior of the blank tool.

Lastly, it is an object of the present invention to provide a new and improved method for a metal forming process for impregnating complex patterns in various tool designs, such as sockets, wrenches and extractors, all of which is susceptible to low cost of manufacturing method with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such a method for commercial manufacturing economically available to the buying public.

These together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

FIG. 1 is a top view of the indexing/rotary table with holders, slide, motor and sensors.

FIG. 2 is s front view of the floating impregnating punch and a knock out punch.

FIG. 3 is a top view of the striper plate shown supporting a proximity sensor that verifies the location of a blank part in the stage one holder.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference now to the drawings, and in particular to FIG. 1 thereof, a new and improved method for a metal forming process that impregnates complex patterns in various tool designs is disclosed herein embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.

Such components for each tool are individually configured and correlated with respect to each other so as to attain the desired objective.

More specifically, the present invention is a new and improved method that impregnates complex patterns in various tool designs. The use of presses and multi stage stamping is a common practice and known to those skilled in the art who are familiar with the basic set up and operation thereof. The presently disclosed method is specifically directed to the particular arrangement of the process steps disclosed herein.

As shown in FIG. 1 is the automatic rotary/indexing table 10. Mounted in the rotary/indexing table are three holders 12, 14, 16 which incase the desired tool design on all sides except for the cavity 18 where the free floating punch (See FIG. 2) is inserted. Each holder is secured by fasteners 20 and four plates 22.

Below the holder in the first possession 1 is a slide support 24 which allows the slide 26 to locate the blank tool under the holders opening 18 by means of a cylinder slide 28. A solenoid 30 raises the blank tool into the cavity of the holder where another sensor (See FIG. 3) verifies the possession of the blank tool. The holders and rotary/indexing table are supported by a backup plate 32.

A motor 34 rotates the rotating/indexing table that contains the holder and a blank tool from possession 1 by means of a drive belt 36 to position 2. A proximity locator 38 locates the rotating/indexing table by means of a grove 40 in the outer edge of the rotating/indexing table. A proximity sensor 42 verifies the location of the rotating/indexing table by means of a metal locator 44 and sends a signal to the PLC.

Once the all the criteria from all the sensors and solenoids have been acknowledged and approved by the PLC, the press cycles bringing the top half of the die set (See FIG. 2) that contains the free floating punch 48 and the knockout punch 66 down. It is at this time that the impregnation of the blank tool takes place in possession 2 and a newly impregnated tool is ejected in possession 3.

As shown in FIG. 2 shows sectional side view of the top half of a die set 46. A punch 48 is seated in a holder 50. The punch is supported by a backup plate 52 all of which rides on a thrust bearing 54 which is supported by the thrust bearing race 56. The middle section 58 of the holder 50 supports a bearing 59 which is supported on both sides by bearing shims 60. Everything from the bearing race 54 to and including the shims 60 is contained in the cavity 61 in the top portion of the die set 46. Part of the holder 50 and punch 48 and end cap 62 and heads of bolts 64 protrude beyond the top half of die set 46. All is supported by the end cap 62. A knock out punch 66 is held by knock out holder 68 and secured by fasteners 70. As the press cycles down a newly impregnated blank tool is ejected by the knock out punch 66.

As shown in FIG. 3 is a striper plate 72 that gives support to the holder 14 in position 2 and holds the part location sensor 76 over holder position 1. Hole 78 allows the knockout punch to pass through and eject the newly impregnated tool out the bottom of holder 16.

With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. 

1. A new and improved method for making specialty tools in which complex patterns are impregnated in various specialty tool designs, said method comprising: a upper end of the die set; a lower end of the die set that is located directly under the upper end die set; and an automatic rotary/indexing table built in the lower end of the said die set which contains three blank tool holders and the automatic rotary/indexing table is moved by a belt in which the other end is connected to a motor and the complete operation including the press is controlled by a Programmable Logic Control better known as a PLC; and a blank tool is incased by a holder all sides except for the opening where the impregnating punch enters and the knock out punch ejects a newly impregnated blank tool.
 2. The method of claim 1 wherein the upper end of the die set contains and supports a knock out punch and a floating impregnating punch that impregnates a blank specialty tool such as a wrench, socket or a specialty tool, the impregnating punch and punch holder is supported by bearings and a backup plate and is free floating horizontally within the desired bounds of the interior side walls of the die set where the punch holder is recessed and the knock out punch ejects the newly impregnated tool from the blank tool holder.
 3. The method of claim 1 and 2 wherein different complex impregnating design punch's can be interchanged in the accommodating punch holder and the blank tool holders are interchangeable. 